Forming method



Sept- 18, 1945- I D. c. KEMERER 2,385,033

FORMING METHODS Filed Nov. 17, 1942 A Trae/Vex Patented Sept. 18, V1945 UNITED` STATI:

s PATENT lorfrncray FoaMlNG METHOD non charles xemerer, non; Benen, oeuf.

Application November 17, 1942, Serial No. 465,844

` (ci. 11i-56) .V 1 Claim.

This invention pertains to methods of obtaining plastic deformation of materials so as to form said materials into the configuration of a die in a rapid and elcient manner. 'I'he invention also pertains to methods whereby fluid pressure impulses varying rapidly in intensity are ,employed in forming materials'into objects hav- 'ing the coniiguration of a die.

The pressing or moldingV of various materials into objects of a desired configuration by the use of rigid male and female dies has in recent years been supplanted -by methods in which one rigid die is employed and the 'material to be molded or pressedis forced against such die by a resilient or elastic member. such as a large block of rubber. It has been found, however, that such molding methods have limitations and are not adapted to the manufacture of objects in dies designed to impart a large number of relatively sharp angles, embossed lor depressed portions, or any appreciable number of relatively fine details. 'I'he prior method appears 'to be successful only in imparting gently curving contours to an object.

The present invention is particularly directed ,-25

to methods whereby. objects provided with ahum- -ber of indentations, angles, depressions, lips, sharp curves and the like may be readily formed.

The method is applicable to the formation of objects not only from Asheet material,.such vas o aluminum, sheet copper and other metals or alloys, but is also applicable to the formation of objects from compositions such as thermosetting or thermoplastic compositions, laminated and fabric, etc.

Generallyl stated, the present invention pertains to a method whereby objects may be formed or molded by xforcing an'elastic member against a material in the direction of a die, such elastic WOOdV 4 member being preferably forced so as to compress the material by means of Ytluid pressure. The elastic membermaybe either unitary or preferably laminated, the laminations being movable relatively to each other so as to permit the outer layers of the `elastic member more readily to conform to details of the die.

In order to causeplastic deformation of the `forming operations simultaneously.

that relatively intricate objects may be quickly and readily formed.

An object of the present invention, therefore, is to disclose and provide methods of facilitating molding and forming operations. T

Another object is to disclose and provide means and methods whereby fluid pressure may be eflfectively employed in forming' objects from various sheet metals, compositions, thermoplastics, laminated bodies, etc.

An object of the present invention is to disclose and provide a method whereby plastic flow and deformation of mtals may be obtained by the use of a pulsating fluid pressure applied to a forming member.

These and other objects, uses and advantages of the invention will become apparent to thoseV skilled in the art from the following detailed description of the invention and certain modiilcations thereof.

In order to facilitate understanding, reference will be had to the appended drawing, in which: 1 Fig. 1 is a sectional view, partly diagrammatic, of an arrangement which may be'employed in the formation of objects from veneers bonded with suitable adhesives or plastics.

Fig. 2 is a vertical section of an improved type of machine adapted to perform a plurality of Fig. 3 is an enlarged vertical section through one of the forming units shown in Fig. 2.

As previously stated, the methods and devices of the present invention are adapted for use with u diagrammatically illustrates one phase of the inmaterial from which the object-'is being made, the method of the presentinvention employs iluid pressure impulses varying rapidly in intensity,

the resulting pulsations causing the material be'-,

details of the die. By'the use ofl a iluid pressure including the rapidly pulsating variable pressure ing acted upon to now into the cavities and other l cated at 3.

, layers of wood veneer bonded by means of a resin,

adhesive, thermoplastic or the like. The individual sheets of veneer may be individually impregnated or may be interlaid with sheets of adhesive or resin.

, As shown in Fig. 1, the lower member or die l is provided withl a smooth inner surfacev 2 upon which the various layers ofvveneer and bonding material are laid, these various layers being indi- Y 'I'he edges of the die I are raised to form a peripheral seating plane, indicated at I. A cover 5 provided with a resilient or elastic member 6 is applied to the lseating plane of the die l latchessuch as the latch l. 'I'he resilient or velastic member 8 maybe arthin sheet of steel or component, plastic iiow of metalsis attained sov 55 other metal and when the unit is rst assembled,

such resilient member 5 is inl contact with the composition 3 being molded. Heating and cooling means, lsuch as the coils 8, may be embedded with or made an integral part of the die I.

Means are provided for supplying fluid pressure to the space between the resilient member 9 and the body of the cover 5, such as for example. a pipe line 9 leading to a source of fluid pressure, not shown. The uid employed is preferably hot oil, water or other liquid and may be supplied from a suitable arrangement of heaters and pumps.- A check valve I3 and a valved outlet line I are provided in the conduit 9.

In compressing the composition 3 into a coherent, strong sheet or object, fluid pressure is admitted through the conduit 9 into the space behind the resilient or elastic sheet 6 so as to force said sheet towards the die I and thereby compress the composition 3. Thermosetting or thermoplastic adhesives are used in the composition 3. Suitable heat is supplied by the useof hot liquids in the conduit 9 and by energizing the heating means 8. The fluid pressure is gradually increased, the resiliency and elasticity of the member 9 permitting such member to move downwardly toward the die and exert suitable pressure gearing from a motor I4. The branch -line I2 is,

of course, filled with fluid and the rapid pulsations of the ram I3 generate fluid pressure impulses varying rapidly in intensity but becoming progressively higher as the pressure of the uid supplied through check valve l becomes progressively higher. Differently stated, the ram I3 acts in ,a manner similar to that of a, water hammer. Since liquids are relatively incompressible, the ramlI3 materially increases the pressure within the conduit 9 and acting upon the elastic member 5. so that the elastic member 6 as well as the composition 3 is subjected to a progressively higher average pressure and to a multiplicity of blows resulting from the pulsating variable pressure component generated by the ram.

At the conclusion of a molding or forming operation, the valved branch line Il is opened and the'pressure existing in conduit 9 is released. The cover 5 is then removed and the molded ob- .lect extracted from the die I. It will be found that the fluid pressure, acting over the entire surface 'of the elastic member 6, has compacted the material 3 into an extremely dense object having contours identical with the surface 2 of the die I.

By referring to Figs. 2 and 3, the adaptation of the meth'od hereinabove described to the formation of objects from sheet metal, will be apparent. The machine shown in Fig. 2 is designed to pressure-form a plurality of sheets of metal into a plurality of objects of desired form. The machine may comprise a base or work table I6 of circular or polygonal plan. Centrally mounted is a pressure cylinder I1 with a ram I3 slidably mounted therein, means being provided, such as the conduit I9, for supplying uid under pressure beneath the ram in order to raise the same. The ram I3 carries a superstructure or platform above the level of th'e base I5 and a plurality of peripherally spaced pressure heads 2| and 22, and the like. These v'pressure heads may be removably attached to the platform 20 as by means of bolts and turnbuckles, generally indicated at 23. The platform 2l may also carry a suitable source of fluid pressure, such as the high pressure pump 2|, the discharge of such pump being connected as by line 25 and suitable branch lines to each of the pressure heads. 'I'he pressure head 2|, for example, may be connected to conduit 25 by means of a coupling 28. A-

rapidly reciprocating ram or pump 21 is connected to the conduit 25 for the .purpose of superimposlng a rapidly pulsating, regulatable pressure to the fluid in vthe conduit 25. It is to be understood that the conduit 25 may be provided with a check valve and a valved discharge line. The platform 20 may also carry a storage tank for fluid and a heater for the fluid if the use of heated fluid is deemed desirable.

As shown in greater detail in Fig. 3, th'e pressure head 2| (exemplary of the other pressure heads which may be embodied in the machine of Fig. 2) is provided with a centering cylinder 30 having an outwardly extending lip 3| having a corrugated upper surface complementary t0 l the corrugations in the lower surface of the edge portion 32 of-the pressurehead 2|. Held between th'ese opposing corrugated surfaces of the lip 3| and edge area 32 is an elastic member 33, these opposing corrugated surfaces being firmly held as by means of bolts 3l. For purposes of illustration, the elastic member 33 is shown as a unitary body which extends downwardly from the inner surface 35 of the pressure head 2| to form a sack or bag-like appendage. 'Ihe conduit 25 is shown connected to the head 2| by means of a locking or gasketing ring 31.

A die 40 having a desired internal surface (shown provided with the inwardly extending rib-like projections 4I) is positioned upon the `work table I8. Positioning of the die 40 may be facilitated by the use of a removable centering ring 42 fitting into a recess formed in the surfaceof the table I6 and adapted to engage a centering die 40 immediately beneath the pressure head 2|. After the die 40 hasbeen properly positioned on the table I6, a sheet of metal from which the nished object is to be formed is placed within the die, as indicated at I3, and th'e ram I8 is lowered so as to lower the platform 20 and the pressure head 2| onto the die. The, cylindrical ring 30 slidably nts around the die 4|) and the lower flange of the ring 30 is locked to the table I3 as by means of the swing bolts 45, such swing bolts being anchored in the bed I3 as by anchors 46.

It is to be understood that four, six or even ten various dies may be mounted upon th'e table I8 so that the various operations described with respect to pressure head 2| and die 40 may be simultaneously taking place at'various peripheral points of the bed I6. After the various pressure heads have been locked to the bed I6 above their respective dies, fluid is supplied to each of the pressure heads by means of the pump 2li and conduit 25. The fluid pressure existing within the sack or appendage formed by lthe elastic member 33 will cause such elastic member 33 to expand and force the sheet of metal 43 into intiateu contact with the inner surfaces of the It is te be understood .that the pressure of rapid pulsation in such pressure so that a rapidly varying pressure of the uid medium takes place while an effective, positive, iluid pressure is at all times maintained against the elastic member 33. The added pulsating pressure generated by the ram 21 causes th'e metal 43 to be drawn over the various ribs, such as 4I, permitting the metal 43 to rapidly conform to the minutest differences in contour existing in the inner surface of the die 40. After a desired maximum pressure has been reached, the fluid pressure within the conduit 25 and pressure head 2l is released by discontinuing the pump 24 and opening a suitable discharge line associated with the conduit 25. 'Ih'e swing bolts 45 are released and the ram i8 is energized so as to raise all of the pressure heads simultaneously, thereby permitting formed objects to be withdrawn from lthe dies 40.

Although in the example given hereinabove the expansible member 33 was stated to be unitary, the expansible member 33 may be made of laminated structure and when so made the outer layer or material, adapted to come directly into contact with the metal being formed, should be relatively soft, elastic and resilient, whereas intermediate or yother layers, although elastic, need not be as soft. By placing the softest layers in contact with the material being formed, greater accuracy and detail is attained. Flexible, impregnated cloth may be used for some of the layers in order to impart necessary strength to the expansible bag.

'I'hose skilled in the art will appreciate that many variations of the present invention may be used. Numerous changes may be made in the arrangement and structure of the machines here disclosed. For example, the ram I8 may be operated hydraulically, pneumatically or even by mechanical means. The positioning ring 42 may be supplanted by registry pins or other means for properly positioning a die beneath the pressure head. Instead of the cylinder 33, other means for holding the head upon the bed Il may be employed. The tumbuckles 23 permit leveling of the pressure head but other means for removably attaching pressure heads to the platform 2l may also be used.

The methods and processes of the present invention are particularly well adapted to the formation of objects from sheet metals. By the term metals" as used herein, reference is madenot only to pure metals such as aluminum, copper and the like, but to the many alloys available 10 for industrial use, such as the aluminum-coppermagnesium-manganese alloys, aluminum-magnesium-silicon alloys, and various other alloys in which these and other metals appear in varying proportions. It may be noted that Duralumin l5 and similar alloys may be most readily formed into desired objects if the forming operation is carried out within one or two hours of heat treatment. Those skilled in the art willl appreciate that some alloys can be most easily worked at low temperatures and before hardening whereas characteristics of the metals being used. In some instances it may be desirable to equip the die 40 with either heating or cooling means so as to permit the forming operation to be carried out under optimum conditions.

All changes, modifications and adaptations coming within the scope of the appended claim are embraced thereby.

I claim: i

A method of forming material into objects having the configuration of a die, which comprises:

placing the material onto a die, covering the material with an elastic member, and forcing said elastic member against the material in the direction of thedie by a gradually increasing average fluid pressure, said average fluid pressure including a rapidly pulsating variable pressure component.

DON CHARLES KEMERER. 

